I have been given a 4 tile modular tile pattern called Kale to lay travertine tiles. The problem is the grout lines are not even.They vary between 0mm-3mm and 6mm depending on the position of the tiles, surely this can’t be right? Any one got any ideas on fixing the problem?

I think the showcase is a great idea! Also, posibly a section to answer questions, like the one above concerning the grout joint variance.

David,
The stone was not cut for that specific pattern.(most tile/ stone is not) Lets say an 8x8 is laying next to a 16x16, they should be the same size, but with the two 8x8's you have an additional grout joint making it take up more space. It does add up and will throw you way off by time you are done with your whole floor. The solution is to either cut each tile, which is very time consuming. Also its hard to cut a small amount off perfectly strait, you have to be carefull not to bend the blade as well. Another solution would be to have bigger grout joints to make the size differance less noticeable. If you have good skills with a 4 inch grinder you can install the bigger tiles together (with no or minimal joints) and after the tile sets, use a 4 inch diamond blade that is the thicness of your desired joint width and cut each joint. This only works if your joints are between 1/16 and 1/8, maybe 3/16. This method is tricky to do without chipping the tile. The easiest solution is making your grout joints bigger. Hope this helps!

Thank you Todd for your help with David's question, as well as the Q&A forum idea.

The 4 piece pattern is typically,8x8, 8x16, 16x16,and 16x24. The edge may be straight, chisselled, or distressed. The sizing is generally good and it can be butt jointed with no joint but if you are setting the distressed or chisseled edge material, the joint size is naturally irregular, much like the visual of tumbled marble on a back splash. The beauty of this stone is keeping the edge detail exposed and I believe the stone looks best either ungrouted or with a minimal grout line.
The thought process is contrary to normal tile installation but if you try to fill the joint up flush, it will be large and irregular.
I installed the distressed edge Kale in my own house with a small grout joint and it looks good and has been easy to maintain.
An electric broom or a vacuum cleaner will pull out any dirt that gets in this low joint.
Good luck!!

I have found a way to use cement board AS the base INSIDE a shower pan. It requires a certain technique that I have a patent pending on and as compared to a Kerdi or similar shower base ,a tile ready base could be constructed for under $200.00 for a 48x34. If anyone has an interest we will be putting up a website soon but until then send me an E-mail to let me know if anyone is curious as to how I do it. pgctech1@aol.com